Starter zero current test apparatus and method

ABSTRACT

An alternator and starter tester system having a starter current zero test. The current is measured before and after a solenoid of a starter motor is energized and deenergized to determine if the starter motor should be failed. This allows the operator to quickly determine if the starter motor is stuck on during normal starter motor testing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No.11/260,184 entitled, “ALTERNATOR AND STARTER TESTER APPARATUS ANDMETHOD,” filed Oct. 28, 2005, which claims priority from U.S.Provisional Application No. 60/622,799, entitled “ALTERNATOR AND STARTERTESTER APPARATUS AND METHOD,” filed Oct. 29, 2004, both of which arehereby incorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention pertains to the field of testing vehicle motorrotary accessory devices. More particularly, the invention relates todevices for testing alternators and/or starter motors.

BACKGROUND OF THE INVENTION

It is well known in the vehicle industry that certain rotary accessorydevices are often used in connection with vehicle motors. Two such wellknown accessory devices are alternators and starter motors. Alternatorsare used in connection with an engine and are belt driven by the engine.Alternators have internal components, which when rotated supplyelectrical power to a vehicle and/or an engine. Alternators aretypically removably but rigidly mounted via a bracket to the engineblock or the chassis of the vehicle. In many cases, where a standardtype of alternating mounting arrangement is used, the alternator has“ears” with holes that are mounted onto a post or belt attached to thevehicle. This permits pivoting of the alternator so that the alternatorcan be pivoted around the post against the belt tension in order toinstall and remove belts, and provide a suitable tension when the beltis installed.

Starter motors are electrical motors, which are typically removably butrigidly mounted to an engine or transmission casing. The starter motorhas an electrically driven pinion gear extending from the starter motorthat engages a component (typically gears on the flywheel of the engine)in order to be able to rotate the crank shaft of the engine to start it.There are a wide range of attachment mechanisms for attaching saidstarter motor.

It is often desirable to test alternators and/or starter motors atlocations where they have been removed from the vehicle, e.g., on a testbench. For example, such testing may be desirable before installing anew alternator or new starter or may be desirable for removing anexisting alternator or starter for testing.

When testing an alternator, it is desirable to attach a belt to a pulleyof the alternator and drive the alternator belt with a motor. Thissituation requires both: (1) a way to securely but removably mount thealternator, and (2) a way to provide belt tensioning. It would bedesirable to have an apparatus and method that is able to convenientlymount the alternator to the overall testing apparatus so that it can bequickly, conveniently, safely, and easily installed and/or removed withrespect to the testing apparatus. It would also be desirable to have anapparatus and method that can quickly, conveniently, safely and easilyprovide tension to the belt that is used to drive the alternator via amotor associated with the testing apparatus.

When testing a starter motor, the starter motor is typically connectedto a device that provides power in order to selectively operate thestarter motor. In such a situation, it is desirable to be able to holdthe starter motor in place in a conventional location during testing.Thus, it would be desirable to have a method and apparatus that canquickly, conveniently, safely and easily provide a mount for the startermotor in a testing apparatus.

Testing of starter motor can be time consuming if during the test, thestarter motor becomes stuck. If the starter motor is stuck, it can leadto inaccurate results. Thus, it is desirable to have an apparatus andmethod of quickly test the starter motor and determine if it is stuckon.

Furthermore, conventional alternator and starter testers have beenfairly complex in operation with limited safety features. This had beenacceptable in the past due to the fact that most parts retailersemployed skilled counter people and kept the test equipment behind thecounters, away from the customers. As retailers have evolved into moreof a merchandising customer-orientated retail environment, they havemoved the test equipment to the front of the store so customers caninteract with store personnel to test these components. The test isconsidered a service for the customers and efforts were needed to makethe results easy to understand for the customer and provide a solutionto the customer's problem. The skill level of the counter person hasdeclined as well due to increased personnel turn over. This resulted ina need for a simplified, yet accurate system to be used.

Retailers and component rebuilders are faced with a high percentage ofthe components that are returned for warranty work, even though thecomponents are actually working properly. This warranty problem can costthe industry millions of dollars each year. Thus, a need exists for anaccurate and easy to use alternator and starter tester apparatus andmethod in order to accurately diagnose the problem.

New alternators are becoming more complex to test. In the past,alternators were very simple in the manner in which they were energizedand regulated. As technology has evolved, the manner in whichalternators are regulated has become more complex and diversified frommanufacturer to manufacturer. Traditional test equipment has handledthis technological evolution with complex and expensive methods.

SUMMARY OF THE INVENTION

The foregoing needs are met, to a great extent, by the presentinvention, wherein in one aspect, an apparatus is provided that in someembodiments an alternator and/or starter motor tester include a starterzero current test.

In accordance with one embodiment of the present invention, analternator and starter tester for testing a starter motor is providedand can include a software that can control a starter zero test, a firstswitch that when closed, can allow power to a transformer, a secondswitch that when closed, can allow power to a solenoid of the startermotor, a current meter than can measure current flowing on a power line,and a processor that can communicate with the software, the firstswitch, the second switch, the transformer, the solenoid and the currentmeter.

In accordance with another embodiment of the present invention, a methodof testing a starter motor can include closing a first switch so thatcurrent can flow to a transformer which can supply current to thestarter motor, measuring current with a current meter before a solenoidof the starter motor is energized, and failing the starter motor ifcurrent is detected above the predetermined level.

In accordance with yet another embodiment of the present invention, analternator and starter tester system for testing a starter motor caninclude a software means that can control a starter zero test, a firstswitch means that when closed, can allow power to a power transformingmeans, a second switch that when closed, can allow power to a solenoidmeans of the starter motor, a current measuring means that can measurecurrent flowing on a power line, and a processing means that cancommunicate with the software means, the first switch means, the secondswitch means, the power transforming means, the solenoid means and thecurrent measuring means.

There has thus been outlined, rather broadly, certain embodiments of theinvention in order that the detailed description thereof herein may bebetter understood, and in order that the present contribution to the artmay be better appreciated. There are, of course, additional embodimentsof the invention that will be described below and which will form thesubject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of embodiments inaddition to those described and of being practiced and carried out invarious ways. Also, it is to be understood that the phraseology andterminology employed herein, as well as the abstract, are for thepurpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conceptionupon which this disclosure is based may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an alternator and starter motor testerapparatus according to an embodiment of the present invention.

FIG. 2 is a perspective view of the alternator and starter testingapparatus of FIG. 1 depicting a protective door cover in a closedposition.

FIG. 3 is a block diagram of the main components of the alternator andstarter testing apparatus of FIG. 1.

FIG. 4 illustrates an alternator cable check method of an embodiment ofthe present invention.

FIG. 5 illustrates the starter zero current components that are used inthe zero current method.

FIG. 6 illustrates the steps of the starter zero current test method.

FIG. 7 illustrates an embodiment of the present invention havingmultiplexing capabilities.

FIG. 8 is a perspective view of the peripheral and remote connections ofthe testing apparatus.

DETAILED DESCRIPTION

The invention will now be described with reference to the drawingfigures, in which like reference numerals refer to like partsthroughout. An embodiment in accordance with the present inventionprovides an alternator and starter tester apparatus for holding andtesting an alternator and/or starter motor that includes a protectivehood or cover, a controller connecting an LCD touch-screen, amultiplexer, an alternator main harness connector, a starter harnessself-test connector, a barcode connector, USB host and USB functionconnectors, an Ethernet connector, and a compact flash connector.Additionally, a starter zero current test and apparatus are included inthe present invention.

An embodiment of the present testing apparatus is illustrated in FIG. 1.FIG. 1 illustrates an alternator and/or starter testing device 10(“tester”) including a housing 12 and a base plate (or chassis) 14. Thehousing 12 surrounds and supports various operative components of thealternator and/or starter testing device 10 including, for example, apower supply, diagnostic electronics, mounting devices, a display, aclosable front cover, and the like. In one embodiment, a monitor screen23, such as an LCD touch-screen may be implemented within the housing 12design. A test power button 25, such as a toggle-switch design, isprovided on the housing 12 to turn the tests on and off. A main powerswitch (not shown) is also used to provide main power to the alternatorand/or starter testing device 10.

The alternator and/or starter testing device 10 also includes analternator belt tensioning arrangement generally designated 16, analternator mounting arrangement generally designated 18, and a starterholder arrangement generally designated as 20. Each of the belttensioning arrangement 16, the alternator mounting arrangement 18, andthe starter motor holder arrangement 20 can be mounted directly to thebase plate 14.

The alternator belt tensioning arrangement 16 and the mountingarrangement 18 together can hold the alternator in place for testing. Aninstallation assembly that includes one or more mounting pins (notshown) can be placed in the mounting arrangement 18 in order to mountthe alternator. The alternator can be horizontally or vertically mounteddepending on the type of alternator. The pins are replaceable to allowflexibility for current and future applications.

A test adapter and power leads can be connected to the alternator inorder to provide test information to the alternator and/or startertesting device 10. Additionally, a drive belt, such as a serpentine or Vbelt and the like, can be connected to the alternator and the motor ofthe alternator and/or starter testing device 10 to simulate thealternator operating environment in the vehicle. A gas piston may beused for belt tension to ensure consistent belt tension during testingand thereby eliminating over tensioning or slipping belts that mayaffect test results.

The starter motor holder arrangement 20 includes a quick release ratchetsystem, wherein the starter is placed on a pad and held in place by theratchet system. The starter motor holder arrangement 20 includes, asupport pad, a handle and a release lock that when operated engages anddisengages a lock (pawl, for example) from the ratchet. The startermotor holder arrangement 20 eliminates straps, uses quick ratchet tohold starter without the need of any additional holding mechanism oruser assistance during the test. Thus, this speeds loading and unloadingof components to be tested. The starter is placed on the pad and theoperator squeezes the release lock and presses down on the handle toengage the starter and then releases the lock so that the lock is againreengaged. Leads, including, for example, battery lead, ground lead,solenoid lead and sense lead are connected to the starter in order toconduct the tests.

FIG. 1 also illustrates the monitor screen 23 that can operate as atouch-screen LCD user interface that communicates with a controller(discussed below) as well as to display information to the user. Theinvention also utilizes an on-line tutorial for quickly training newpersonnel on the unit's functionality and on-line help screens to helpnew users navigate and test components during a test. The LCDtouch-screen offers step-by-step instructions for setting up the testerand conducting tests. The tester 10 can also include on-screen hook updiagrams and a specification library database, which eliminate the needfor paper flipcharts and enables software updates for new alternatorapplications or starter configurations. This database can be updated bycompact flash, flash drive, other memory media or remotely via a networkconnection (discussed below). The monitor screen allows users to runadvertising screens when the tester is not in use. These screens can beuploaded to the tester from a user's network server or uploaded from acompact flash or other memory media. Additionally, the screen is capableof displaying information in various updatable languages.

The alternator and/or starter testing device 10 outputs “Good/Bad” or“Pass/Fail” results to the user. A user printout that details testresults and provides technical advice for other potential problems, ifthe component tested as good or pass, can be provided to the user.

FIG. 2 is a perspective view of the alternator and starter testingapparatus of FIG. 1 depicting a protective door cover in a closedposition. In one embodiment, the alternator and/or start testing device10 incorporates enhanced safety features, such as the protective doorcover 22 to enclose moving parts during tests. The protective door cover22 conceals the belt tensioning arrangement 16, the alternator mountingarrangement 18, the starter motor holder arrangement 20, and the testcomponents, such as an alternator or starter motor from the operator.The protective door cover 22 of the alternator and/or starter testingdevice 10 is shown covering at least the belt tensioning arrangement 16,the alternator mounting arrangement 18, and the starter motor holderarrangement 20 in the closed position.

In the closed position, the protective door cover 22 eliminates thepossibility of hands getting caught in moving parts or projectiles frombeing thrown towards customers or store personnel. In anotherembodiment, the protective door cover 22 has a door interlock switch(not shown) to disable tests while the protective door cover 22 is open.In still another embodiment, the protective cover includes a viewingwindow so that the operator can observe the testing components duringthe tests.

FIG. 3 is a block diagram 300 of the components of the alternator and/orstarter testing device 10. The major components include an monitorscreen (23), such as LCD screen 302 to display various information tothe user. The LCD screen can also be a touch panel to input informationas desired by the user and can be controlled by a processor 304. Anothercomponent is the processor 304, which can be any processor orcontroller, including a FPGA (Field Programmable Gate Array). Theprocessor is capable of running various OS (Operating System) includingLinux, Apple Computer's Operating System (such as OS X), Windows,Windows CE and the like. The processor 304 also communicates with adigital signal processor 306, which includes an A/D converter.

The processor can be configured to communicate with an internal 308 andexternal 310 memory. The memory can be any memory including, forexample, compact flash, SD (secure digital), USB flash drives, and thelike. A USB (universal serial bus) port 312 can communicate with theprocessor 304 and provides a connection for various USB devices, suchas, for example a printer 314 or external memory drives. Additionally,RS-232 ports 316 can also communicate with other external devices, suchas a computing device (laptop) 320 or a bar code reader 318. Thecomputing device 320 can be any computing device, including a personalcomputer, a PDA (personal digital assistant), a cell phone and the like.The bar code reader 318 allows the user to scan from a bar code that maybe attached to the test component various information, such asalternator/starter type, serial numbers, manufacturer and the like.

The processor 304 can also interact with a networked computer, LAN(local area network) or a distributed network, such as the Internet 322and the like. This connection allows the user to update the tester andalso send information regarding the test results to a remote location.The updated information can include, software, firmware, languages anddatabase for the components to be tested or to the tester 10.

A motor 330 is also provided in order to test alternators. Motor 330 cansimulate the engine of a vehicle and includes a pulley to mate with abelt. At one end, the belt is coupled to the motor 330's pulley and atthe other end is coupled to the pulley of the alternator to be tested.

FIG. 4 illustrates an alternator cable check method 400 embodiment ofthe present invention. Currently there is no effective way of verifyingthat a test lead or connecter used to test an alternator is actually agood test lead. Because there are many different alternators with manydifferent mechanical style electrical connectors, providing aconventional matting connector to conduct a loop-back test would not bea convenient or economical solution. To overcome this problem, asoftware is provided to keep track of the number of times in sequencethe tester fails an alternator, which uses a specific connector. Thesoftware keeps track of how many times a specific connector has failedsequentially when used with that type of alternator. If a preset numberof failures is met, then software will “lock out” that specificconnector so that it can not be used in later testing. The operator canenable the “locked” connector by getting a known good alternator andre-running a test. If the test passes (i.e., the adapter is actuallygood), then the adapter can be re-enabled and be used in future tests.

Turning to FIG. 4, which illustrates method 400 that starts at step 402.The user selects the component or the part to test at step 404 throughan input device, such as the LCD screen. At step, 406, the softwareidentifies the cable connector to the user. In the case of analternator, the alternator connector is identified for the user. At step408, the software detects whether the alternator connector is “lockedout.” That is, the software will not allow the alternator to be testedwith that connector. If yes 410, then the user is instructed via the LCDscreen to perform a test with the connector on a good (known)alternator. If the connector passes, then the software “unlocks” theconnector at step 414. When the connector is unlocked, it can again beused to test alternators. If the connector fails, then the connectorremains “locked.”

Turning back to step 408, if the connector is not locked 416, then thetester proceeds to test the component or part at step 418. At step 420,the software will note whether the alternator passes or fails. If pass422, then clear any fail counts for this specific connector at step 424.If the alternator fails 426, then an increment counter is started forthis specific connector at step 428. At step 430, the softwaredetermines whether or not the connector has failed for a certain numberof times. The number of times can be determined by the user and canrange, for example, from 1-5, from 1-7, and another ranges desired bythe user. If the maximum limit has not 432 been reached, then the methodend at step 434 until the next test. If the maximum limit has beenreached 436, then the connector is locked out at step 438. When theadapter is locked out, it can be discarded or returned to themanufacturer. As stated above, the adapter can be “unlocked” if itpasses another test using a good alternator. This method prevents theuser from continue to use bad connectors that may provide inaccuratetest results. Additionally, this method can also prevent good connectorsfrom being discarded unless it fails a certain number of times.

Referring to FIGS. 5 and 6, in some embodiments, a starter zero currenttest is provided to determine if a starter motor's solenoid breaks powerto the motor when the start signal is removed from the starter. Asolenoid start signal is made switchable separate from the main batterypower to the starter. The main battery power current is monitored forzero current before and after the solenoid is activated and deactivated,respectively. If current is detected in either case the starter isconsidered to be stuck on and thus fails the test.

FIG. 5 illustrates the starter zero current components 500 that may beused in the zero current method. A first switch 502, when closed, allowspower to a transformer 504. A second switch 506, when closed, allowspower to the solenoid 508 of a starter motor 510 for testing. A currentmeter 512 monitors the current in line 514.

FIG. 6 illustrates the steps that may be involved in the starter zerocurrent test 600. At step 602, the method starts by having the userinput information regarding the starter motor to be tested. The testerconfigures itself for the test that needs to be conducted including thestarter zero method. At step 604, the software can direct the DSP or theprocessor to activate the first switch to allow power to thetransformer. At step 606, the zero current check is conducted todetermine if any current is flowing. If yes 608, then fail the starter.At this point, minimal current (5-10 amps) should be flowing and if thecurrent exceeds a certain limit, such as about 40 amps, then the startershould be failed. If no 612, then at step 614, energize the startermotor's solenoid by activating the second switch. At step 616, recordthe test data and store the data into memory. At step 618, the solenoidis de-energized by deactivating the second switch and the transformer isalso de-energized. Again, the current check is conducted at step 620 andif yes 622, then fail starter at step 624. If no 626, then proceed tostep 628, wherein the starter motor can pass or fail depending on themeasured data.

The present invention uses improved test leads to ensure accurate testresults and increased lead life. The tester utilizes BERNDY connectors,which demonstrate an improved strain relief and have molded ends on highuse cables. The tester apparatus has the ability to perform selfcalibration, which eliminates the need for external calibration,ensuring the repeatability and accuracy of tests conducted in the field.Furthermore, the tester apparatus can measure alternator diode ripplepattern accurately and catches faults with a rectifier bridge that couldother wise go undetected.

The tester also includes internal signal generation, which can emulatethe signal of vehicle computers based on alternator part numbereliminating the need for expensive external adapters. This feature maybe required for modern computer controlled vehicles that have the carson board computer control or monitor charging output.

In some embodiment, the present invention comprises circuitry thatenables programmable switching or multiplexing of the test circuit forconnection to the desired pin in the connector on the alternator. Thisallows the use of one adapter cable for most if not all alternators witha specific connector regardless of the alternator connector pinlocation. This embodiment allows the tester to configure itselfinternally to adapt to connector configurations that have differentwiring (pin-out) requirements for different test applications.Additionally, this embodiment eliminates the need for multiple adaptercables with different wiring pins, reduces the total number of cablesrequired and eliminates confusion of the operator that occurs whenselecting the correct cable for a particular component or test.

Alternators typically have up to six electrical connections, of whichtwo are connections for positive and negative of the battery. The otherfour connections may be various voltage regulation functions. Multiplealternators use the exact same physical connector for these batteryconnections but change the location of a specific electrical circuit inthe connector based on manufactures' discretion. This required theoperator to use of various adapter cables (as many as 50 differenttypes) based on various of physical configurations of variousalternators in order to connect the correct test circuit to the correctpin in the connector.

FIG. 7 illustrates an embodiment of the present invention havingmultiplexing capabilities. Multiplexer 700 generally includes varioustest components for an alternator system, such as ignition 706, stator710, sense 712 (battery+signal), lamp 714, and field driver signal 716.A person skilled in the art would recognize that the multiplexer canreceive any signal from the component under test as desired by the user.Alternator cable 702 and relay cable 704 can be connected to a printedcircuit board in the tester or any other place on the tester as desired.The multiplexing system includes software that controls the variousrelays and the signal received during testing from the alternator basedon the type or model of the alternator. Although described for analternator, the multiplexer can be used with the starter motor.

The relay cable 704 can control the various switches depending on thedesired pin from which the test signal is to be received. Ignition 706includes four switches 706A, 706B, 706C, and 706D, which allows signalsto be received from five pins instead of having three switches that canreceived signal from four pins. As ignition 706 is shown, the switches706A, 706B, 706C, and 706D are set so that signals from pin 5 of theconnector that is connected to the alternator is being received by thetester. If the ignition signal is on pin 1, then the software willcommand switch 706A to connect at the top gate (3,4) and disconnect atthe bottom gate (5,6) and command switch 706B to connect at the top gate(3,4) and disconnect at the bottom gate (5,6).

Stator 710 includes three switches 710A, 710B, and 710C that allowsaccess to four pins. As stator 710 is shown, the switches 710A, 710B,and 710C are set so that signals from pin 3 of the connector that isconnected to the alternator is being received by the tester. Sense 712includes three switches 712A, 712B, and 712C that allows access to fourpins. As sense 712 is shown, the switches 712A, 712B, and 712C are setso that signals from pin 4 of the connector that is connected to thealternator is being received by the tester.

Lamp 714 includes three switches 714A, 714B, and 714C that allows accessto four pins. As lamp 714 is shown, the switches 714A, 714B, and 714Care set so that signals from pin 1 of the connector that is connected tothe alternator is being received by the tester. Field driver signal 716includes three switches 716A, 716B, and 716C that allows access to fourpins. As field driver signal 716 is shown, the switches 716A, 716B, and716C are set so that signals from pin 2 of the connector that isconnected to the alternator is being received by the tester.

In operation, the user can input the information (type, model number,etc.) regarding the alternator under test through an input device, suchas the LCD screen or other input devices and the tests that are to beconducted. Based on the information inputted, the software can configurethe multiplexing circuits and so that signals from the right pin will bereceived by the tester. For example, if the sense signal from thealternator under test will be on pin 1, then the software can instruct,via relay cable 704, for switch 712A to connect top gate (3,4) anddisconnect bottom gate (5,6), and for switch 712B to connect top gate(3,4) and disconnect bottom gate (5,6). This will allow signals at pin 1to be received at the sense 712. The multiplexer 700 can have as manyswitches as needed and is not limited to the ones shown. For example,there can be 1 to 2 switches or 5 to 8 or more switches.

In other embodiments, the multiplexing software can verify theinstruction inputted by the user and performs a series of safety checksbefore performing any multiplexing actions. For example, somepotentially dangerous requests by the user will be declined by thesoftware, such as a request from user to connect B+(sense) directly tothe field circuit of an alternator. The software can also protect thetester by probing some voltages on the alternator to detect any fatalproblem with the alternator. For example, some signal pins on thealternator may be already shorted to ground. Thus, the software will notperform any multiplexing action in order to avoid shorting the testercircuit to ground.

As stated above, in some embodiments of the alternator and startertester apparatus, a bar code port is provided. The bar code port mayserve to operably connect a bar code reader (not shown) to amicroprocessor or controller. In some embodiments, the bar code port maybe a conventional component, such as an RS-232 port. The bar code readermay be, for example, a conventional optical bar code reader, such as agun or wand type reader.

The operator swipes or aims the bar code reader onto a bar code that isassociated with the particular starter or alternator to be tested andreads the bar code accordingly. The bar code itself may be affixed tothe alternator or starter at the time of manufacture, purchase orservice. The bar code may contain information, or point to informationstored in a database. Examples of remotely located databases includedata based accessible by the Internet, Ethernet, or other remote memorystorage facility.

The bar code may provide a variety of information regarding thealternator or starter to be tested. For example, the bar code mayprovide information regarding the electrical specifications, maintenanceinformation, serial number, lot number, warranty information, and/or amanufacture data code. This data can be used to select parameters forthe test cycle run in the alternator and starter tester apparatus. Thedata provided by the bar code is not limited to the examples given.

In some embodiments, the printer port may print bar code labels that maybe attached or otherwise associated with the alternator or starter andprovide updated information. The updated information may include, amongother things, service dates, service procedures, and warrantyinformation (e.g., time left on warranty, who was the originalpurchaser, what types of service are and are not warranted, etc.). Theprinted label may then be read by the bar code reader in subsequenttests cycles. These features can eliminate possible typographical errorsduring manual input and by speeding up part number selection and entryby having a scanning capability.

The present invention also has the ability to store and display or printtechnical bulletins associated with specific part numbers of componentsto be tested. Printouts of test results can give rebuilders access todata obtained by users to assist in the further analysis of thatcomponent.

Referring to FIG. 8, in some embodiments of the alternator and startertester apparatus, network connectivity may be used to track tests basedon part number, employee and location in order to improve and enforcewarranty reduction programs. The large scale communication network portcan be constructed and arranged to receive an information relay device,such as an Ethernet wired module and/or an Ethernet wireless module. TheEthernet modules communicate at data rates of 10 Mbps (10Base-TEthernet), 100 Mbps (Fast Ethernet), 1000 Mbps (Gigabit Ethernet) andother data rates. The Ethernet modules can relay information between thealternator and starter tester apparatus and another device connected tothe modules via a wire or wirelessly. The information relayed caninclude data from the result of an alternator and/or starter test, thepart's warranty information, the part type, the part make and model,previous tests, updates, diagnostic or operating parameters of thealternator and starter tester apparatus, maintenance data of thealternator and starter tester apparatus, and any other data required bythe operator.

Referring to FIG. 8, in some embodiments, peripheral module ports may beused to communicate to various peripheral devices such as a mouse, akeyboard, or a printer as well as to receive updates and/or downloadsfrom a connected device such as a laptop or personal computer. Theperipheral module ports may be a USB module having ports for a hostconnection and a function connection. The USB module may communicate asUSB 1.1 or USB 2.0 or other data rates. The host connection mayaccommodate a mouse, a keyboard, or a printer. The function connectionmay accommodate a laptop or personal computer.

The many features and advantages of the invention are apparent from thedetailed specification, and thus, it is intended by the appended claimsto cover all such features and advantages of the invention which fallwithin the true spirit and scope of the invention. Further, sincenumerous modifications and variations will readily occur to thoseskilled in the art, it is not desired to limit the invention to theexact construction and operation illustrated and described, andaccordingly, all suitable modifications and equivalents may be resortedto, falling within the scope of the invention.

1. An alternator and starter tester for testing a starter motor,comprising: a software that controls a starter zero test; a firstswitch, when closed, allows power to a transformer; a second switch,when closed, allows power to a solenoid of the starter motor; a currentmeter that measures current flowing on a power line; and a processorthat communicates with the software, the first switch, the secondswitch, the transformer, the solenoid and the current meter.
 2. Thetester of claim 1, wherein the starter zero test determines if thestarter motor fails by monitoring current before the solenoid isenergized.
 3. The tester of claim 1, wherein the starter zero testdetermines if the starter motor fails by monitoring current after thesolenoid is energized and deenergized.
 4. The tester of claim 1, whereinthe starter motor fails if current is detected after the first switch isclosed and current is supplied to the transformer.
 5. The tester ofclaim 1, wherein the starter motor fails if current is detected afterthe second switch is closed and the solenoid is energized anddeenergized.
 6. The tester of claim 4, wherein the starter motor failsif the current is above about 40 amps.
 7. The tester of claim 5, whereinthe starter motor fails if the current is above about 40 amps.
 8. Amethod of testing a starter motor, comprising: closing a first switch sothat current can flow to a transformer which supplies current to thestarter motor; measuring current with a current meter before a solenoidof the starter motor is energized; and failing the starter motor ifcurrent is detected above a predetermined level.
 9. The method of claim8, further comprising: closing a second switch to energize the solenoidof the starter motor; recording test measurements of the starter motor;deenergizing the solenoid; and measuring current with the current meterafter the solenoid is deenergized to determine if the current is abovethe predetermined level.
 10. The method of claim 9, further comprisingpassing or failing the starter motor based on the recorded testmeasurements.
 11. The claim 8, wherein the predetermined level is about40 amps.
 12. The claim 9, wherein the predetermined level is about 40amps.
 13. An alternator and starter tester system for testing a startermotor, comprising: a software means that controls a starter zero test; afirst switch means, when closed, allows power to a power transformingmeans; a second switch means, when closed, allows power to a solenoidmeans of the starter motor; a current measuring means that measurescurrent flowing on a power line; and a processing means thatcommunicates with the software means, the first switch means, the secondswitch means, the power transforming means, the solenoid means and thecurrent measuring means.
 14. The tester system of claim 13, wherein thestarter zero test determines if the starter motor fails by monitoringcurrent before the solenoid means is energized.
 15. The tester system ofclaim 13, wherein the starter zero test determines if the starter motorfails by monitoring current after the solenoid means is energized anddeenergized.
 16. The tester system of claim 13, wherein the startermotor fails if current is detected after the first switch means isclosed and current is supplied to the power transforming means.
 17. Thetester system of claim 13, wherein the starter motor fails if current isdetected after the second switch means is closed and the solenoid meansis energized and deenergized.
 18. The tester system of claim 16, whereinthe starter motor fails if current is above about 40 amps.
 19. Thetester system of claim 17, wherein the starter motor fails if current isabove about 40 amps.
 20. The tester system of claim 13 furthercomprising a memory means for storing the software means.